Wall structure



c. K. Roos wLL STRUCTURE July 24, 1934.

2 Sheets-Sheet l Filed Dec. 23, 1933 .uff l..

c. K. Roos WALL STRUCTURE July '24, 1934.

Filed DSG.I 23 1933 2 Sheets-Sheet 2 Parenteel July 24, 1934 UNITED STATES PATENT oFFlcE WALL sraUcrUnE Carlisle K. Roos,'Wheaton, Ill., aissignor to United States Gypsum Company, Chicago, Ill., a corporation of Illinois lAppiimtimn December z3, 1933, serial No. 703,731:

13 Claims.

' foraminated metal, such as so-called expanded metal lath and wherein means is provided, in conjunction and cooperation with such lath, for increasing the fire resisting and other advantageous characteristics of the wall structure.

It is an object of the present invention to pro-v vide a wall structure and plaster supporting element for cooperation with other elements therein whereby the escape of normal moisture through or from the wall under the influence of heat is retarded and-whereby the major portion of the radiant energy will be reflected thereby providing a wall of great strength and high heat and moisture insulating characteristics.

A further object is to provide a`wall structur combining an unusual number of desirable and advantageous characteristics Withoutv materially increasing the Weight or thickness of the walls and, at the same time, enabling the ordinary workman to build a satisfactory Wall in the usual well known manner and without the necessity of learning a new technique or acquiring special knowledge;

Further objects will be apparent from the specications-and the appended claims.

In the drawings:

Fig. lv is a fragmentary perspective vertical section of/ a wallstructure illustrating an embodiment of the invention. v

Fig. 2 is a perspective view of one of the lath and illustrates the arrangement of the component parts thereof and the method of fastening them together.

' Fig. 3 is a fragmentary vertical section through one of the lath in which a somewhat different type of foraminated metal is used. v

Fig. 4 is a fragmentary transverse section through one o-f the lath in which expanded metal is used and in which the metal is indented and the fabric with foilbacking is secured thereto at the indentations. A Referring to the drawings in detail, the'embodiment illustrated therein,` and particularly inFig. ,l 1, comprises a double wall structure including the usual vertical studding l which may be the ordinaryZ'.' x 4" material or any other suitable support ordinarily used in building construction.

In order to provide a suitable plaster support, sheets of specially constructed lath 2, such as illustrated in Fig. 2, are secured tothe wall stud- `ding in the usual manner as by nailing or stapling and the usual plaster coating isapplied thereto. In Fig. 1, a double wall construction is shown, and having a plastered innersurface and a brick veneer outer surface. This construction Will be described in detail later.

Each lath 2 comprises a sheet of expanded,

reticulated or foraminated metal 3 having secured to the back side thereof a sheet of fabric 4 which latter may be of a suitable material such as so-called kraft paper or chip paper. l

Prior to the application of the fabric to the expanded metal, `one of the surfaces of the fabric is covered with a metal coating 5, preferably aluminum foil,- for purposes hereinafter specifled. The coating 5 may be applied and secured snugly to the paper in intimate contact therewith and in any suitable manner, preferably by a suitable adhesive such as asphalt, sodium silicate solution, ora dextrine adhesive. The foil may be firmly secured to the board by these or other adhesives and by applying heat or pressure or both in a suitable and well known manner. The

sheet, of metallized fabric 4 is slightly smaller than the expanded metal lath as shown inFig. 2, and is secured thereto by means of staples 6. The bight portion of the staple is preferably against the metallized side of the fabric and the prongs extend through the fabric and the mesh of the expanded metal and may be bent over and clinched on the mesh. The adjacent ends of the prongs may be given a slight locking twist as shown in Figs. 1 and 3 or may be merely clinched over the mesh. as in Fig. 4.

In applying the fabric to the expanded metal lath the fabric is placed thereon with the foil side exposed and in alignment with one side and one end of the reticulated metal allowing a narrow strip of the metal at the opposite side and end to be exposed for overlapping of the-lath. The

- reticulated or foraminated metal used may be any of the usual types used for metal lath, but is preferably expanded metal and may be provided with the/*usual ribs or corrugations if desired which may be of the type shown at 7 in Fig. 3, or with indentations 8 as in Fig. 4.

In securing together the component elements of the lath, the fabric isapplied to that side of the foraminated metal sheet from ,which the corrugations or indentations extend, thereby providing portions between these corrugations or indentations spaced slightly from the fabric, whereby when plaster is applied to the expanded metal, it will completely fill the space between the mesh and the fabric thereby efficiently locking or keying the plaster coating in place. Even when expanded metal without ribs or other self-furring means is used portions of `the mesh will normally be spaced somewhat from the paper backing. This, and also the pressure of the workman on the plaster in the normal act of plastering, will cause the plaster to be effectively keyed to the mesh.

As previously mentioned, Fig. 1 illustrates a double wall construction having a brick veneer outer surface and a' plastered inner surface, although a single wall structure will be satisfactory in many instances and the lath constructed as described herein may be used onlyon the plastered side of the wall and the other side may be of any desired construction.

In the double Wall shown, the above described lath sheets 2 are secured to both sides of the studding 1 by means of suitable fasteners and with the foil or metallizing coating adjacent the studding thereby providing a foil enclosed insulating air space in the wall. A plaster coating 9 is applied to the inner surface of the wall in the normal manner and a plaster coating 10 is applied to the outer surface simultaneously with the laying of a brick veneer 11 whereby the brick veneer and the lath are all secured together by the plaster coating therebetween. The air space between the two heat reflecting foil coatings x assists inrproviding an efficient heat insulating,

re and moisture resisting wall structure.

The `plaster coating is applied to the mesh with its fabric and foil backing, in a moist condition,- and, when dried, the plaster is interlocked with the mesh and also adheres snugly to the fabric backing thus assisting in strengthening the wall structure.

The metal foil 5, as previously stated, adheres snugly to the paper backing and, being waterproof, effectively prevents the escape of moisture through the wall, this foil also being an efficient heat reflector with low emissivity, thus assisting in providing a wall with heat and moisture insulating characteristics of a high order.

'Ihe metallizing coat applied to the paper is preferably very thin aluminum, although other materials may be used. In any case a metal capable of providing bright surface is' used in order that the heat reflecting characteristics of such a surface may be taken advantage of. The amount of metal in such a coating is small, and little heat is thus lost either by conduction or by convection currents.

When a wall structure such as disclosed herein is subjected to high temperature for a prolonged time, as in certain tests now required ofbuilding structures, the heat calcines the plaster beginning at the outer surface and progressing inwardly, but at a reduced rate by reason of the fact that the heat required Ato dehydrate or calcine the plaster tends to prevent further rise of the temperature of the plaster until its calcination is completed.

Since calcined plaster is a good heat insulator, an appreciable time is required before the calcination reaches the stage and the plaster reaches the temperature at which any effect on thepaper or fabric backing of the lath is noticeable. As

the temperature rises to the ignition point, the paper or fabric would ordinarily burst into a name, but by virtue of the covering of the calcined plaster on one side and the foil covering on the other, excess of atmospheric oxygen to the paper or fabric is prevented with a result that only a sort of dry distillation takes place. 'I'his dry distillation results in the charring or carbonization of the paper or fabric converting the same into a more or less coherent layer of carbon which in itself has heat resistant value if the layer can be maintained in position in the wall. The foil coating 5 on the back of the fabric adheres closely to this carbonized layer and is secured, together with the fabric, to the reticulated metal by means of the staples 6. Also, the plaster, being more or Y calcination of the plaster. Carbonization of the fabric is retarded due to the fact that the moisture therein is retained by the foil backing; therefore, all of the moisture in the fabric and plaster must be given off through the plaster thereby delaying complete calcination and carbonization and materially lengthening the life of the structure.

Although a comparatively small number of the fastening staples 6 may be used forsecuring the foil covered fabric to the reticulated metal, the area between any four adjacent fasteners is relatively small and the fabric, as well as the plaster between the fabric and reticulated metal, is retained in place for a maximum length of time even after prolonged exposure to high temperature, by the comparatively small, well secured areas of foil between the staples.

To assist in retaining the foil in place during andafter carbonization of the fabric and to prevent the fasteners or staples 6 from cutting through the foil or fabric in the clinching process, washers 12 may be used and the prongs of the staples passed therethrough, as shown in Fig. 4, in which is illustrated the same construction as in Fig. 2, except that the foraminated metal 3 is provided with spaced indentations 8 to which the fabric and foil backing is -secured and which provides a space 13 between the foraminated metal and thebacking which will be filled in the normal act of plastering thereby keying the plaster securely inplace in the same manner as previously described.

A wall structure built in accordance .with this invention is particularly eflicientv in thatzit provides, in a comparatively inexpensive easily built structure, a wall having great strength and resistance against shock as well as being proof against wind and air inflteration and substantially a complete insulation against heat, cold, moisture, dust and vermin both large and small, as well as being an emcient fire retarder and an insurer against sudden changes of room temperature. Other advantages might be enumerated, but it is obvious that in the practice of this invention, more desirable characteristics may be incorporated in a simple, inexpensive, andpeculiarly efficient structure than has heretofore been possible in the art.

While only certain specific embodiments of the invention have been shown and described herein, it will be readily understood by those skilled in the art that changes and modiflcationsin the de- For instance; instead of using aluminum foil, a

relatively thin metallic covering of other types or materials may be used if desired. It will also be understood that the claims are not intended to be specically construed except as required by the prior art, and that the terms used comprehend a proper range "of equivalents, e. g., the term wall including ceilings as well as vertical walls, etc.

Having thus described my invention, what I claim and desire to secure by Letters Patent is:

1. A building wall structure comprising supporting members, plaster supporting foraminated metal sheets overlying a plurality of said supporting members and secured thereto with their vrear surfaces facing hollow wall spaces, the rear surface of each sheet being substantially completely covered with a fabric secured thereto and having a heat reflective metal coating substantially coextensive and in intimate contact therewith on the side facing the wall space.

2. A building wall structure comprising supporting members, plaster supporting foraminated metal lath secured thereto with their rear surfaces facing hollow wall spaces, the rear surface of each lath being substantially completely covered with a laminated fabric secured thereto and comprising a paper sheet coated with aluminum foil in intimate contact therewithr on the side facing the wall spaces, said paper sheet and foil being substantially coextensive.

3. A building wall structure comprising-supporting members, plaster supporting laminated sheets secured thereto with their rear surfaces facing hollow wall spaces, said sheets comprising in the order recited a sheet of foraminated metal lath, a sheet of fabric secured to and substantially completely covering one side of said lath, and metal coating having high heat reflecting characteristics covering and adhering to the opposite side of said fabric, and facing said wall spaces, -said fabric and metal coating being substantially coextensive.

4. A building wall structure comprising supporting members, a plaster supporting laminated sheet secured thereto with its rear surface facing hollow wall spaces, said sheet comprising in the order recited, a sheet of expanded metal lath,

a sheet of paper securedy to and substantially completely covering one side' of said expanded metal' lath, and a heat reective metal coating applied tothe side of said paper opposite said metal lath and facing said wall spaces, said paper sheet and coating being substantially coextensive and said .metal, paper and metal coating being secured together to form a unitary structure.

5. A wall structure of the character described comprising supporting members, a plaster' supporting laminated sheet secured thereto with its I Ymetal and being substantially coextensive therecomprising" supporting members, a plaster supporting laminated sheet secured thereto with its rear surface facing hollow wall spaces, said laminatedsheet comprising a layer of paper, a layer ofaluminum foil adhering to one side of said paper and in intimate contact therewith and facing said wall spaces, and a layer' of expanded metal lath on the opposite side; spaced securing said paper and foil thereon and said expanded metal together in a manner to provide compara.- tively small f oil areas between any four adjacent securing means, and a coating of plaster on said expanded metal and lling the space between said paper and the mesh of said expanded metal. '1. A laminated insulating plaster supporting lath for wall structure comprising, a. sheet of foraminated metal, a sheetof semi-rigid fabric secured to one side thereof in a manner to allow the insertion of plaster therebetween to interlock with the foraminations of said metal, and a. coating of metal having high heat reflecting characteristics and snugly adhering to the opposite side of s'aid fabric and being substantially coextensive therewith, said foraminated metal,

fabric and coating being held together to form a. 1

lunitary structure.

8. A laminated plaster supporting lath for a wall structure comprising. a sheet of expanded metal, a sheet of paper secured to one side thereof in a manner to allow the insertion of plaster therebetween to interlock with the mesh of said metal in the normal act of plastering, and a covering of aluminum foil snugly adhering to the side of said fabric lopposite said expanded 1 with, said expanded metal, paper andfoil being held together at relatively closely spaced points to form a unitary structure.

9. A building wall construction having hollow -wall spaces and comprising supporting members 1 and plaster supporting lath secured thereto, said lath comprising a paper-like sheet [of brous material having one face metallized and having its opposite face covered with expanded metal secured thereto and having portions of its mesh 1 spacedl from said fibrous sheet, said metallized face of said sheet of fibrous material facing said wall spaces, said brous material and expanded I metal being held together at relatively closely spaced points to form a unitary structure. y

10. In a material for receiving and retaining a plaster covering, the combination with foram-v inated` metal, of a paper backing sheet in close relation therewith and acting to close the clench of the plaster with the metal and to adhere 1 snugly to the plaster, and a. sheet of aluminum foil snugly adhering to the rear surface of the paper backing and being substantially coextensive therewith, said metal, paper and foil beying held together at relatively closely spaced 1 l pointsto form a. unitary structure.

11. A building wall structure comprising supporting members, a covering of plaster-supporting foraminated 4metal over said supports, the rear surface of said foraminated metal being substantially completely covered with fabric secured thereto, a coating of plaster on said foraminated metal and in intimate contact with said fabric, and a substantially continuous heat reflective metal coating secured on the rear surface of said fabric and substantially coextensive therewith and arranged to retard the `escape of the water of crystallization under the influence of heat.

12. In a material for receiving and retaining 1 Low/,aos

rear surface facing hollow wall spaces, said element comprising a fibrous backing sheet. accating of metal having high heat reecting characteristics adhering to and substantially coextensive with one side of said sheet and in intimate contact therewith and facing said wall spacing, and a relatively closely spaced metallic reinforcement intimately associated with said brous sheet and adapted to become embedded in plas'- ter applied to one side of said sheet, said sheet, metallic coating, and reinforcement being secured together to form a unitary structure.

CARLISLE K. ROOS.

- CERTIFICATE or CORRECTION.

Patent No. l, 967, 905.

July 24, 1934.

CARLISLE K. ROOS.

It is hereby certified thal error appears in the printed specification of the above numbered patent requiring correction as follows: Page 3, line 83, claim 6, -after "securing" insert the words means securing; and that the said Letters Patent should be read with this correction therein that the same may conform to the krecord of the case in the Patent Office.

Signed and sealed thislllth day of September, A. D. 1934.

(Sed) Leslie Frazer CERTIFICATE Patent No. l, 967, 905.

Low/,aos

rear surface facing hollow wall spaces, said element comprising a fibrous backing sheet. accating of metal having high heat reecting characteristics adhering to and substantially coextensive with one side of said sheet and in intimate contact therewith and facing said wall spacing, and a relatively closely spaced metallic reinforcement intimately associated with said brous sheet and adapted to become embedded in plas'- ter applied to one side of said sheet, said sheet, metallic coating, and reinforcement being secured together to form a unitary structure.

CARLISLE K. ROOS.

0F CORRECTION.

July 24, 1934.

CARLISLE K. ROOS.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 3, line 83, claim 6, -after "securing" insert the words means securing; and that the said Letters Patent should be read with this correction therein that the same may conform to the krecord of the case in the Patent Office.

Signed and sealed thisillth day of September, A. D. 1934.

(Sed) Leslie Frazer 

